System of modular construction and assembled structure

ABSTRACT

A system of modular construction including a plurality of pre-manufactured components cooperatively structured for onsite assembly of a building or other structure. A plurality of modules are disposed and structured to at least partially define wall, floor and roof portions of the assembled building, wherein the plurality of modules are interconnected in an intended relation to one another by a connecting web assembly, wherein the connecting web assembly comprises a plurality of different types of component connectors and retaining channels. A water distribution assembly is incorporated within the building such that water is delivered by gravity feed to a plurality of plumbing fixtures and/or outlets and the building also includes an integrated, built-in gutter assembly associated with the plurality of down spouts for the recognized distribution and/or collection of water.

CLAIM OF PRIORITY

The present application is based on and a claim of priority is madeunder 35 U.S.C. Section 119(e) to a provisional patent application thatis currently pending in the U.S. Patent and Trademark Office, namely,that having Ser. No. 61/338,204 and a filing date of Feb. 16, 2010, andwhich is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is directed to a system of modular construction for theonsite assembly of any one of a plurality of different buildingstructures, which may be least partially self-contained. A plurality ofpre-manufactured components including a plurality of modules areinterconnected by a connecting web assembly comprising a plurality ofappropriately structured and disposed component connectors, bracketsand/or retaining channels which collectively facilitate the assembly ofthe building structure.

2. Description of the Related Art

In the construction industry associated with domestic as well ascommercial buildings, consumers demand a wide variety of architecturalstyles, floor plans, etc. dependent on individual desires and/orpractical applications for which the buildings are to be used. Asconventionally built, various types of “raw materials” and/or componentsare utilized to construct a building at a given location site, utilizingpartially trained as well as skilled craftsmen, such as carpenters,brick masons, plumbers, electricians, etc.

However, due to periods of economic decline over the years, conventionalconstruction techniques and materials have been found to be expensive,labor intensive and time consuming. As a result, the building industryespecially, but not exclusively, in recessionary times suffers fromsignificant declines in demand. Attempts to overcome such situationshave resulted in modifications in materials with an attendant reductionin cost and/or labor requirements in the assembly of such buildingmaterials. Some innovations are considered to at least partiallyalleviate problems associated with conventional building constructiontechniques. However, major problems still exist, at least in terms ofcost, labor, construction time etc.

Accordingly, more ambitious attempts to overcome problems of the typegenerally set forth above include the introduction of prefabricatedbuildings designed for use as either commercial or residentialstructures. As such, components used in prefabricated buildings aretypically manufactured in a factory or other facility where massproduction techniques can be employed. After production, such componentsare shipped to any number of building sites using common commercialcarriers. Therefore, while the industries relating to prefabricatedstructures have enjoyed at least a moderate success, the specificapplication and/or utilization of such prefabricated buildings has beensomewhat limited.

Moreover, a number of disadvantages associated with prefabricatedbuilding systems include a limitation or restriction in design, whereinthe plurality of prefabricated building components are not universallyadaptable for multiple designs, floors plans and/or a variety ofpractical uses. As a result, consumers interested in prefabricatedbuildings are often provided with a limited number of options. Also, atleast some of the conventional or commercially available prefabricatedbuilding systems still require the use of relatively skilled labor dueto the complexity or sophistication of the building materials or theirassembly into a completed structure. Furthermore, unless prefabricatedstructures are assembled in accord with relatively demandingspecifications, problems associated with their use or occupancy includeleaks, the accumulation of condensation, structural deterioration ordamage, temperature control, noise insulation and a variety of othersituations not normally associated with conventional buildingconstruction techniques.

Therefore, there is a need in the building industry for a system ofmodular construction which includes a plurality of pre-manufactured orpre-formed building components cooperatively structured to facilitateonsite assembly and formation of a variety of different buildingstructures. Moreover, the resulting building structures should overcomeknown disadvantages and problems relating to wear, maintenance costs,and time of assembly. Also, a preferred and proposed system of modularconstruction should be capable of producing a building structure whichis at least partially self-contained at least regarding energyrequirements, water management and/or plumbing, etc. Finally, theoverall cost factors associated with materials, highly skilled labor andassembly time should be minimized, regardless if the assembled buildingis used for domestic or commercial applications.

SUMMARY OF THE INVENTION

The present invention is directed to a system of modular constructionfor the onsite assembly of any one of a plurality of differentstructures specifically, but not exclusively, including buildingstructures. As set forth in greater detail hereinafter, the system ofthe present invention includes a plurality of pre-manufacturedcomponents which are to be incorporated within the structure or buildingto be assembled.

More specifically, the plurality of building components include aplurality of modules cooperatively disposed and structured to define anouter or peripherally disposed wall portion, a floor portion, a roofportion and in at least one or more preferred embodiments and interiorpartition portion. As such, the plurality of modules comprise aplurality of wall modules, a plurality of floor modules, a plurality ofroof modules and a plurality of partition modules. However, it is to benoted that the various, pre-manufactured components of the building orstructure to be assembled may include a plurality of other componentssuch as, but not limited to, those associated with a water distributionassembly, a mounting assembly for a solar panel system, a gutter and adown spout assembly, etc.

Further with regard to the roof portion, at least one additionalembodiment of the subject invention includes the forming or constructionof the plurality of roof modules by a unitary molding procedure. Assuch, the plurality of roof modules may include a substantially onepiece, molded construction, wherein the outer surfaces thereof do notrequire any decorative facing material. Moreover, this type of unitary,molded construction facilitates the use of the roof portion,specifically including the plurality of roof modules, with or as part ofa variety of buildings and/or building systems in addition to thesubject modular building system of the present invention.

The assembly of the building or like structure is facilitated throughthe provision of a connecting web assembly which comprises a pluralityof brackets or “component connectors”. Each of the component connectorsis cooperatively structured with at least some of the plurality ofmodules or other components of the building with which they are used, toestablish tongue and groove connections between the component connectorsof the connecting web assembly and/or between adjacently disposed orotherwise interconnected modules or components. In addition, theconnecting web assembly includes a plurality of retaining channelsdisposed in interconnecting, retaining relation to at least commonlyused once of the plurality of modules, such as the plurality of wallmodules defining the outer peripheral wall or other portions of thebuilding structure. Therefore, the plurality of component connectors orbrackets and the plurality of retaining channels are cooperativelydisposed and structured relative to the plurality of modules, and othercomponents of the building structure, to secure the wall portion, floorportion, roof portion, etc. to one another in a manner which facilitatesthe assembly of the building or like structure.

As will become more apparent hereinafter, the plurality of componentconnectors, of which the connecting web assembly is comprised, may varyin structure and disposition dependent, at least in part, on thestructure and/or disposition of the plurality of building componentsbeing connected to one another or otherwise assembled. Morespecifically, one type of the component connector includes a tonguemember integrally or otherwise fixedly secured to a mounting plate. Thetongue and mounting plate are disposed in at least a transverse relationto one another but in certain preferred embodiments, in a perpendicularrelation to one another. Moreover, the tongue portion of this typecomponent connector includes a free end and a substantially planarconfiguration which facilitates its insertion into groove or slot formedin one of the building components or modules being assembled. As aresult, the insertion of the tongue into the groove of the buildingcomponent facilitates the establishment of the aforementioned tongue andgroove connection. In addition, the mounting plate associated with sucha tongue and plate component connector is disposed to be interconnectedor engage another building component. As a result, the tongue and platecomponent connector interconnects two or more building components by theestablishment of a tongue and groove connection with one component and amounting plate connection to a correspondingly disposed other one of theconnected building components.

Yet another type of component connector includes a key structure havinga substantially planar configuration and oppositely disposed free ends.As such, the key structure is insertable into different grooves ofcooperatively disposed building components, such as modules, to beconnected to one another. While the preferred embodiment of this keystructure type of component connector preferably includes a planarconfiguration, other configurations may be used for such a keystructure. By way of example, different end or side portions thereof maybe angularly oriented to one another, such as when the angled keystructure connects modules together which have a relative angulardisposition or orientation.

As set forth above, the connecting web also includes a plurality ofretaining channels. In at least one additional embodiment of theconnecting web assembly one or more of the retaining channels includes atongue structure extending outwardly therefrom. The associated tonguestructure is also dimensioned and configured to facilitate the insertionthereof into the correspondingly disposed groove of a module or buildingcomponent which is to be attached to or interconnected by theaforementioned retaining channel associated with the tongue structure.

Further with regard to the connecting web assembly, the plurality ofretaining channels preferably includes a first number of retainingchannels. The first number of retaining channels are disposed inretaining, supporting and/or interconnecting relation to a lower end ofa plurality of correspondingly disposed wall modules, which define atleast a portion of the outer or peripheral wall of the buildingstructure. One or more of these first numbers of retaining channels mayinclude the aforementioned tongue structure, as described above, so asto facilitate the interconnection of the wall portion of the buildingstructure to a foundation portion thereof.

The plurality of retaining channels also includes a second number ofsuch retaining channels which are disposed in interconnecting, retainingrelation to the upper end of correspondingly disposed wall channels. Asa result, the plurality of wall modules are retained in assembledrelation to one another at least partially by the disposition of thefirst and second number of retaining channels disposed along the lowerends and upper ends respectively.

Additional structural and operative features associated with theconnecting web assembly is the provision a supporting flange or “ledger”integrally or fixedly connected to at least some of the lower endretaining channels. The supporting flange extends transversely outwardfrom the corresponding retaining channel(s) towards and into theinterior of the building being assembled. As such, the support flange(s)has a sufficient transverse and longitudinal dimension to support and/orbe connected to corresponding ends of a plurality of floor modules. Assuch, the plurality of floor modules are supported in interconnectingrelation to one another to define the floor portion of the assembledstructure and the flooring on the interior of the building. Accordingly,the opposite ends of correspondingly position ones of the connectedfloor modules are disposed in supported relation on the support flangeassociated with the lower end retaining channels.

As set forth above, the building structure of the present invention mayalso include a roof portion, at least partially defined by a pluralityof interconnected roof modules. The roof modules may be secured to oneanother, as set forth in greater detail hereinafter, utilizing one ormore of the different types of component connectors. In addition, one ormore of the upper end retaining channels, connected to the upper end ofthe assembled wall modules, may be disposed in retaining, supportingand/or interconnecting relation to the roof modules defining the roofportion. In addition, the roof portion may include a plurality of rooftrusses disposed in underlying but supporting relation to the pluralityof connected roof modules. Moreover, roof trusses are disposed insupported and/or interconnected relation to the upper end retainingchannels by virtue of a retaining strap or “hurricane strap”. Theretaining strap is integrally or fixedly secured to one or more of theupper end retaining channels.

Additional features associated with the roof portion include theformation of the plurality of interconnected roof modules into aplurality of roof sections. As such, at least two of the roof sectionsmay define a sloped roof structure, wherein corresponding inner ends ofthe two roof sections are interconnected in overlapping relation to oneanother through the provision of a ridge cap. The ridge cap may also bestructured to at least partially define tongue and groove connectionswith the corresponding sides or ends of the roof sections.

Accordingly, the system of modular construction of the present inventionfacilitates the building or assembly of any of a plurality of differenttypes and styles of building or other structures at an onsite location.The assembled building may also include additional structural and/oroperative features which facilitate it being at least partiallyself-contained. More specifically, the plurality of interconnected roofmodules may include an exterior, exposed mounting structure whichfacilitates the attachment of solar panels thereto. Also, the assembledbuilding structure may include a water distribution assembly, whichfacilitates the collection and distribution of water throughout thebuilding structure to the various plumbing fixtures and/or water outletsby means of gravity feed. Also, the water distribution assembly mayinclude “built-in” or integrated gutter structures disposed within theroof portion in a manner which overcomes the disadvantages and problemsassociated with externally attached gutters. Moreover, the integratedgutter assembly may include a plurality of down spouts which direct thewater to a disposal location or collection facility exteriorly of thebuilding, in order to supply water to the water distribution assembly.

These and other objects, features and advantages of the presentinvention will become clearer when the drawings as well as the detaileddescription are taken into consideration.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature of the present invention,reference should be had to the following detailed description taken inconnection with the accompanying drawings in which:

FIG. 1 is a perspective view of one of a possible plurality of buildingsor other structures assembled onsite utilizing the system of modularconstruction of the present invention.

FIG. 2 is a perspective view in partial cutaway disclosing a floor,foundation and stanchion support assembly of the building of theembodiment of FIG. 1, when partially assembled.

FIG. 3 is a perspective view of at least a portion of the embodiment ofFIG. 2 in partially assembled condition.

FIG. 4 is the sectional view in partial cutaway of wall, floor andfoundation portions of the building of FIG. 1 in at least partiallyassembled condition.

FIG. 5 is a sectional view in partial cutaway of at least a portion ofthe embodiment of FIG. 4.

FIG. 6 is a sectional view in partial cutaway of additional details ofthe embodiment of FIGS. 4 and 5.

FIG. 7 is a sectional view in partial cutaway of an interconnectingjunction between two adjacent modules.

FIG. 8 is a sectional view in partial cutaway and in exploded form of aplurality of modules to be interconnected to form a roof portion of thebuilding of FIG. 1.

FIG. 9 is a detailed view in partial section and cutaway of theembodiment of FIG. 8 in assembled form.

FIG. 10 is a sectional view in partial cutaway of the roof and wallportions of the building of the embodiment of FIG. 1 in an at leastpartially assembled form.

FIG. 11 is a sectional view in partial cutaway of roof sections of aroof portion of the building of the embodiment of FIG. 1, disposed ininterconnected relation by a ridge cap.

FIG. 12 is a sectional view in partial cutaway of the connection of atleast one of a plurality of partition modules disposed on the interiorof the building of the embodiment of FIG. 1.

FIG. 13 is a sectional view in partial cutaway and exploded form of aplurality of partition modules prior to assembly.

FIG. 14 is a sectional view in partial cutaway and exploded form ofutility facilities associated with at least one partition module of thetype generally represented in FIGS. 12 and 13.

FIG. 15 is a sectional, detailed view in partial cutaway of a waterdistribution assembly associated with the building of the embodiment ofFIG. 1.

FIG. 16 is a sectional view of at least one preferred embodiment of thepresent invention associated with one or more wall modules incorporatingsupport stanchions and exterior surfaces thereof.

FIG. 17 is a front plan view of the embodiment of FIG. 16.

FIG. 18 is an end view of wall extensions and corresponding roof andwall portions of the building of the embodiment of FIG. 1.

FIG. 19 is a sectional view in partial cutaway of the attachment of wallextensions and structures associated with the roof portion of thebuilding of the embodiment of FIG. 1.

FIG. 20 is a perspective view of an at least partially assembled portionof one embodiment of the building structure of FIG. 1 incorporatingstructural features of the embodiment of FIG. 19.

FIG. 21 is a perspective view in partial cutaway of yet anotherembodiment of a piling structure defining at least a portion of afoundation assembly of the type represented in FIG. 1.

FIG. 21A is a front plan view of the embodiment of FIG. 21 includingadditional structural features for connecting one or more pilings to andin supporting relation with corresponding wall modules.

Like reference numerals refer to like parts throughout the several viewsof the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As represented in the accompanying drawings, the present invention isdirected to a system of modular construction including a plurality ofpre-manufactured components which are cooperatively structured foronsite assembly of a building or other structure generally indicated as10 in FIG. 1. As emphasized herein, the size, style, floor plan, etc. ofthe building can vary significantly while still being able to be formedand assembled using the various preferred embodiments of the modularconstruction system of the present invention.

The aforementioned pre-manufactured components which define the variousparts of the building 10 include a plurality of modules cooperativelydisposed and structured to define an outer wall portion, generallyindicated as 12; a roof portion, generally indicated as 14 and a floorportion, generally indicated as 16, throughout the various accompanyingfigures. In addition, the building 10 includes a foundation, such as,but not limited to a plurality of pilings 18 disposed in supportingrelation to the remainder of the building 10, on a ground or otherappropriate supporting surface.

The plurality of modules include a plurality of wall modules 20 disposedin adjacent, interconnecting relation to one another so as to extendabout the periphery of building 10 and thereby define the outer wallportion 12. As also represented in FIG. 1, at least some of the wallmodules 20 include window and/or door openings, as at 21 and 22,appropriately positioned to provide both visual and physical access tothe exterior of the building 10. Moreover, at least one embodiment ofthe present invention includes the window and door openings 21 and 22being integrally formed in the wall modules 20 such as by being moldedtherein during the formation or production of the corresponding wallmodules 10. As a result, problems and disadvantages associated with theon-site cutting and/or similar formation of such window and dooropenings is eliminated.

Similarly, in at least one embodiment, the roof portion 14 comprises aplurality of roof modules 24 also appropriately interconnected to oneanother in adjacent relation, so as to collectively define the roofportion 14 of the building 10. Moreover, in at least one preferredembodiment of the present invention the building 10 may be structured tohave a sloped roof portion 14 comprising at least two roof sections 26and 28 joined and/or interconnected at their correspondingly disposedupper or inner sides by a ridge cap 30. As will be explained in greaterdetail hereinafter, the oppositely disposed lower or outer sides of eachof the roof sections 26 and 28 are supported on or at leastinterconnected to the upper ends of the wall portion 12.

Other structural components included within the assembled buildingstructure 10 are generally represented in FIGS. 2, 3 and 20 and comprisea plurality of substantially vertically oriented stanchions 31 formed ofa material having performance characteristics sufficient to providerequired strength and structural integrity to the assembled buildingstructure 10. In addition, the stanchions 31 are disposed generallyabout the periphery of the building 10 in spaced relation to one anotherand are disposed in at least partially interconnecting relation betweenthe lower and upper ends of the wall portion 12 and may also beconnected to retaining channels 40.

As also represented in FIGS. 2 and 3, the aforementioned floor portion16 comprises a plurality of adjacently interconnected floor modules 17which may vary in size and configuration and which collectively definethe floor portion 16 of the building 10. Moreover, as represented inFIG. 6, the outer or exposed surface of the floor module 17 may comprisean integral, molded surface and/or a plurality of separate tiles orother decorative and utilitarian flooring components, as at 19.

Additional features of the assembled building structure 10 include aconnecting web assembly comprising a plurality of component connectorsor brackets 32 and 32′. Each of the component connectors or brackets 32and 32′ are appropriately structured to define tongue and grooveconnection between adjacent and or otherwise interconnected componentsof the building structure including, but not limited to the variousfloor modules 17, wall modules 20 and/or roof modules 24. As representedin FIG. 4 one category of component connectors or brackets 32 includes atongue and plate structure comprising a tongue 34 integrally orotherwise fixedly secured to a mounting plate 34′ in perpendicular orother transverse relation thereto. As such, the tongue 34 of the tongueand plate component connector 32 is dimensioned and configured to beinserted within an appropriately formed groove, as at 35, in any of thebuilding components to which it is to be connected. As a result, atongue and groove connection, as set forth above, is thereby defined.Cooperatively, the plate 34′ of the tongue and plate component connectoris disposed in interconnecting relation to other components of thebuilding 10 as also represented in FIG. 4. Such a connection may befurther facilitated a plurality of fasteners 37 extending through theplate and/or other components to which the tongue and groove componentconnector 32 serves to interconnect.

Yet another structure for attaching pilings 18 to correspondinglydisposed wall modules 20 utilizing the retaining channels 40 isrepresented in FIGS. 21 and 21A. More specifically, this preferredembodiment includes a piling cap 150 secured to the upper end of acorresponding piling 18 and maintained on the upper end thereof by aconnector 37, in the manner described with reference to FIG. 4.Moreover, the interconnecting assembly as represented in FIG. 21Aincludes a connecting plate 134 and a plurality of appropriateconnectors 152. Connectors 152 may be in the form of pass through boltswhich serve to interconnect the plate 134 to the base portion of thereceiving channel 40, as at 40′. These same pass through bolts wouldpass through appropriate apertures formed in the plate 134 and furtherpass through correspondingly aligned apertures 154 formed in the exposeupper base portion 154′ of the piling cap 150. As such, the connecting,bolts 152 would be secured to the base 40′ of the retaining channel 40,be connected to and/or pass through the plate 134 and also through theapertures 154 in the base 154′ of the piling cap 150 and into the piling18. As an alternative structure, the connectors 152 could be integrallysecured to the exposed base 150′ of the piling cap 150 and protrudeoutwardly therefrom. Such integrally secured connectors 152 would passthrough the plate 134 and be bolted or otherwise fixedly secured to thebase 40′ of the retaining channel 40.

As also represented in FIGS. 7 through 9 and 13 the plurality ofcomponent connectors may also comprise the aforementioned key structure32′ preferably including a planar or other appropriate configuration.Opposite ends 32″ of the key structure are substantially free so as tofacilitate there insertion into appropriate grooves, as at 33, formed inthe various components of the building structure 10 which are to beconnected to one another by the key type 32′ component connector. Assuch, the aforementioned tongue and groove connections are establishedbetween adjacent and/or other correspondingly disposed componentsincluding, but not limited to, common use modules such as floor modules17, wall modules 20, roof modules 24, etc.

As also represented in FIGS. 7-9, utilization of the key type componentconnector 32′ is also part of establishes a connecting junction,generally indicated as 38. The connecting junctions 38 are disposedbetween adjacently or interconnected modules such as, but not limitedto, roof modules 24. The connecting junction 38 is defined not only bythe tongue and groove connection established by the key componentconnector 32′ but also by the inclusion of an adhesive or other typeadhering or bonding material 39. The bonding material 39 has sufficientadhesive or bonding characteristics to form a tight leak and/or weatherresistant seal between the correspondingly disposed ends or portions ofthe interconnected modules 24, and in a preferred embodiment at all ormost locations such as, but not limited, to a joint, seam, etc. wheresuch a weather resistant seal is of benefit.

In addition, the aforementioned web connecting assembly also comprises aplurality of retaining channels 40 and 42. More specifically, a firstnumber of the retaining channels 40 are disposed in supporting and/orretaining engagement to the lower end of the plurality of wall modules20 commonly used to define the outer periphery wall portion 12. Incooperation therewith, a second plurality of retaining channels aredisposed in retaining and/or supporting relation to the upper end of thecommonly used wall modules 20 as represented in FIG. 10.

With initial reference to FIGS. 4 and 6, a first plurality of lower endretaining channels 40 include a generally U-shaped cross sectionalconfiguration dimensioned and configured to receive the lower end 40′ ofthe wall modules 20. As such, the lower ends 20′ of each of these commonuse modules 20 may be recessed or otherwise structured such that theouter sides of the lower end retaining channels 40 are disposed insubstantially flush relation to both the outer and inner surfaces of theplurality of wall modules 20 which they engage. In the embodiment ofFIG. 4, the lower end retaining channels 40 are interconnected to afoundation portion or piling 18 using one or more of the tongue andplate component connectors 32 and interconnecting fasteners 37. Incontrast, others of the plurality of lower end retaining channels 40include an integrally or fixedly formed tongue segment 40′ which isdisposed, dimensioned and configured to be inserted within a groove 35formed in the foundation or piling 18.

As also noted, each or at least some of the lower end retaining channels40 include a supporting flange or “ledger” 41 integrally or fixedlysecured to one side thereof and extending outwardly from thecorresponding retaining channel 40 towards the interior of building 10as clearly demonstrated in both FIGS. 4 and 6. Each of the supportingflanges or ledgers 41 extend along a sufficient length or acorresponding retaining channel 40 to engage and at least partiallysupport corresponding ends 17′ of floor module 17. Therefore, at leastthe lower end retaining channels 40 serve to interconnect correspondingwall modules 20, floor modules 17 and the foundation portion, such aspilings 18, to one another in a stable and secure manner. Such stabilityis further enhanced through the inclusion of at least one or morepractically a plurality of fasteners 37 which extend throughpredetermined portions of the lower end retaining channels 40 as well asthrough the lower ends 20′ of the plurality of wall modules 20 and floormodules 17. The fasteners 37 may vary in size, structure andconfiguration depending upon their intended use and placement tofacilitate a secure and stable interconnection between the plurality ofbuilding components included within the assembled building structure 10.

Further with regard to the embodiment of FIG. 6 additional structuralfeatures incorporated within the floor portion 16, such as relates toits support and overall construction, include the provision of floorjoists 45 disposed in supporting relation to a plurality of floor module17. More specifically, each of the opposite ends of the one or morejoists 45 are secured to a foundation or piling member 18 by means of ajoist hanger 45′. In turn, the joist hanger 45′ is mounted on orconnected in partially supported relation by corresponding ones of thepilings 18. Recessed or undercut portions 45″ are provided to include aflush, cooperatively configured engagement with the elongated supportingflange or ledger 41 received therein. This further facilitates thesupport of the plurality of the floor modules 17 on the plurality ofjoists 45, as also represented in FIG. 6.

With primary reference to FIG. 10, the second plurality of retainingchannels are defined by the upper end channels 42 secured in retainingrelation to the upper end 20″ of the common use plurality of wallmodules 20 defining the outer wall portion 12. In addition, the upperend 20″ of the plurality of wall modules 20 and the upper end retainingchannels 42 are disposed in interconnecting, at least partiallysupporting relation to the plurality of roof modules 24 and a pluralityof corresponding roof trusses 48. As set forth above, in the embodimentof the building 10, the roof portion 14 includes at least two roofsections 26 and 28 having an outer or lower end 28′. The lower ends 28′and/or adjacent portions thereof are at least partially supported,retained or otherwise interconnected to the upper end 20″ of theperimeter wall portion 12 by the plurality of the upper end retainingchannels 42. As represented, plurality of retaining structures such asretaining straps or “hurricane” straps 49 are fixedly connected to anappropriate portion of at least some of the retaining channels 42 andare connected to corresponding ones of the roof trusses 48. As such, theouter ends 48′ of the roof trusses 48 are retained by or at leastpartially supported on the exterior of the corresponding upper endretaining channels 42 and maintained in such supported or retaineddisposition due to the interconnection of the retaining strap orstructure 49.

As also represented in FIG. 10, the exterior or exposed outer surface ofthe roof portion 14, specifically including the outer surfaces of theroof modules 24, may include one or more exposed surface structures 19′formed as an integral, molded part of corresponding one of the roofmodules 24. Also, the materials from which the roof modules are formedmust be approved so as to not contaminate any collected water, passingover and/or along the outer surface structure, as such collected wateris to remain potable, as discussed with regard to FIG. 15. In addition,a mounting assembly 50 may be disposed on each or a predetermined numberof the roof modules 24. The mounting of assembly 50 includes anappropriate connector 37 and a mounting base 52 which is disposed andstructured to facilitate the attachment of a solar panel assembly. Assuch, the mounted solar panel assembly renders the assembled building 10at least partially self contained in terms of energy requirements.

Further with regard to the roof portion 14, at least one preferredembodiment of the subject invention includes the forming or constructionof the plurality of roof modules 24 by a unitary molding procedure. Assuch, the plurality of roof modules 24 may include a substantially onepiece, molded construction, wherein the outer surfaces thereof do notrequire any decorative facing material, such as on the exposed portionsof the surface structures 19′. Moreover, this type of unitaryconstruction facilitates the use of the roof portion 14, specificallyincluding the plurality of one piece roof modules 24, with a variety ofbuildings and/or building systems other than the subject modularbuilding system of the present invention.

Yet additional features represented in FIG. 10 include the provision ofthe integrated or “built-in” gutter assembly generally indicated as 54.The gutter assembly 54 includes a support and/or retaining bracket 55and an inwardly extending, depending trough 56. As such, rain water maybe collected in the integrated or built-in gutters 54, 56 and directedto a collection facility or otherwise away from the building 10utilizing a plurality of down spouts 57.

With primary reference to FIG. 11, additional structural featuresrelating to the roof portion 14 and the interconnection ofcorrespondingly disposed inner or upper ends of the roof sections 26 and28 are represented. As set forth above, elongated roof ridge cap 30includes two outwardly extending connecting flanges 30′ which areinserted within correspondingly disposed and configured elongatedgrooves 30″. As such, ridge cap 30 accomplishes the aforementionedtongue and groove interconnection with each of the corresponding upperends of the roof sections 26 and 28. Additional stability is provided bya plurality of connectors 37 passing through portions of the groovedroof modules 24 into a center beam 60 disposed in supporting relation tothe crown or apex of the roof portion 14 defined by the connected innerends of the roof sections 26 and 28.

Yet additional features of the roof portion 14 are represented in FIGS.18-20 and include the provision of wall extensions 62 covering the gableends or other exposed areas of the underside of the roof portion 14.More specifically, the wall extensions 62 are connected to and at leastpartially supported by corresponding ones of the upper end retainingchannels 42 as represented in FIG. 19. More specifically, an extensionchannel segment 64 may be integrally or otherwise fixedly secured to anouter exposed face or portion of the corresponding ones of the upper endchannels 42. Such extension channel segments 64 are disposed anddimensioned to receive a lower or other appropriate portion 62′ of thewall extensions 62 therein. An appropriate fastener 37 passes throughthe extension channel 64 and through the corresponding ends 62′ of thewall extensions 62.

Yet additional features of at least one preferred embodiment of thebuilding structure 10 incorporating the features of the modularconstruction system of the present invention are represented. Morespecifically, the interior space or area of the building 10 may besegregated by a plurality of partition modules 70 and 70′ which may varyin size, configuration and location dependent upon the intended floorplan of the interior of the building 10. The plurality of partitionmodules 70 and 70′ may be interconnected to the outer peripheral wallportion 12 and/or the floor portion 16 utilizing the aforementionedtongue and plate component connector 32 or key structures 32′. As aresult, appropriate tongue and groove connections are establishedbetween the common use partition modules 70, 70′ or cooperativelydisposed and structured modules as at and including partition module 70and wall modules 20 as represented in FIG. 12. Moreover, one or more ofthe plurality of partition modules 70 may include utility structuressuch as wiring or ventilation conduits, etc. generally represented as74. As a result, the one or more partition modules 70 maybeappropriately structured to include interior recesses or chambers 75dimensioned and configured to enclose the utility components 74. Coverplates 75′ maybe used to close or cover the chamber 75 and the utilitycomponents 74 contained therein. As represented in FIG. 13 the variouspartition modules 70 and 70′ may have a variety of differentconfigurations so as to enhance the versatility of the modularconstruction system of the present invention in determining or designingthe interior segmented space area and/or floor plan.

FIG. 15 is a schematic representation of a water distribution assemblywhich may be associated with the building 10 and which, in cooperationwith the aforementioned solar panel assembly, facilitates the building10 being at least partially self-contained and/or self sufficient. Morespecifically, a water collection tank or other facility 80 is disposedat an elevated location above the fixtures or other upper portions ofthe building 10. A supply conduit as at 82 may direct water into thecollection facility 80 and delivered by a pump or by other means from apredetermined water source. In addition a plurality of distributionconduits 84, which may vary in number and location, are disposed influid communication with the water collection facility 80. Moreover,each or at least predetermined ones of the distribution conduits 84 areconnected to or otherwise disposed in fluid communication with aplurality of water outlets, plumbing fixtures, etc., schematicallyrepresented as 86. As a result, water is supplied to the variousplumbing fixtures or water outlets 86 throughout the building 10 fromthe water collection facility 80 by gravity feed through thedistribution conduits 84. The use of gravity feed distribution ofcollected water provides free flowing water to the outlets 86, asrequired.

Additional structural details of the wall modules 20 are represented inFIGS. 16 and 17, including internal structuring thereof. Accordingly, inat least one preferred embodiment, one or more of the wall modules 20include a skin or surface 21 which is intended to be disposed on theinterior of the building, as versus the exterior thereof as representedas 21′. More specifically, the exposed, surfaces 21′ and 21 may beformed or at least partially comprised of a fiberglass laminate orplastic material suitable for supplying the required strength, rigidity,physical properties, etc. necessary to meet appropriate building codesand ordinances. In addition, an inner layer of material, such asplywood, is indicated at 90 and is provided to further enhance therigidity, impact resistance and load carrying abilities of each of theplurality of wall modules 20. Additional strength and load carryingcapabilities are provided in the structuring of the wall module 20through the provision of a plurality of spaced apart inner core supports31. Interior core supports 31 are disposed in a substantially verticalorientation and laminated or adhered to the plywood or other material90, as set forth above. In addition, the modules external skins orsurfaces 21′ and 21 are structured to form a webbing of support tofurther enhance the strength of the modules so formed. Additionally,interior cavities that remain after the placement after theaforementioned material 90 may be filled with appropriate foam or othermaterial. This will result in all interior open areas or chambersreceive such insulating foam.

Once cured, the foam will not only add to the insulating characteristicsof the module 20 but further facilitates the overall rigidity thereof.Finally, in a preferred embodiment the exterior surfaces or skins 21′and 20 may be finished with appropriate architectural embellishmentsincluding, but not limited to, a painted, gel coated finish. Finally, aportion or end of the wall module 20 that is inserted withincorresponding ones of the retaining channels 40 is appropriately taperedand secured therein, at least in part, due to an additional adhering orbonding material 39 as discussed with reference to the embodiment ofFIGS. 7 and 8.

Accordingly, the system of modular construction of the present inventionincludes the interconnection of a plurality of pre-manufacturedcomponents which are cooperatively structured, as set forth above foronsite assembly. As a result the plurality of building components,including but not limited to, the plurality of modules as well as thosecomponents associated with the connecting web assembly facilitate theformation and assembly of any of a plurality of differently designedbuildings. Also, it is emphasized that the system of modularconstruction of the present invention is not necessarily limited to theformation and assembly of a “building” of the type designed forconventional use as represented in FIG. 1. To the contrary, theversatility of the modular construction system of the present inventionallows for the formation and assembly of a variety of differentstructures that may or may not be used as a conventional building havinginterior areas intended to be occupied by an individual.

Since many modifications, variations and changes in detail can be madeto the described preferred embodiment of the invention, it is intendedthat all matters in the foregoing description and shown in theaccompanying drawings be interpreted as illustrative and not in alimiting sense. Thus, the scope of the invention should be determined bythe appended claims and their legal equivalents.

Now that the invention has been described,

1. A system of modular construction including a plurality ofpre-manufactured components cooperatively structured for onsite assemblyof a building, said system comprising: a plurality of modulescooperatively disposed and structured to define an outer wall portion, afloor portion and a roof portion of the building, a connecting webassembly, comprising a plurality of component connectors cooperativelystructured with at least some of said plurality of modules to define aplurality of tongue and groove connections, said connecting web assemblyfurther including a plurality of retaining channels disposed ininterconnecting relation to at least common-use ones of said pluralityof modules, and said plurality of component connectors and saidplurality of retaining channels cooperatively disposed and structured tosecure said wall portion, said floor portion and said roof portion toone another, in a manner at least partially defining an assembledbuilding.
 2. A system as recited in claim 1 wherein at least some ofsaid retaining channels include at least one of said componentconnectors integrally secured thereto.
 3. A system as recited in claim 2wherein said building further includes a foundation; said one componentconnector being inserted within a foundation portion of the building todefine a tongue and groove connection therewith.
 4. A system as recitedin claim 1 wherein at least one of said retaining channels includes asupporting flange extending outwardly therefrom into supporting relationwith at least one of said modules associated with said floor portion ofthe building.
 5. A system as recited in claim 4 wherein said oneretaining channel has an elongated configuration of sufficient length tosupportingly engage a plurality of said modules associated with saidwall portion of the building; said one support flange extending along asufficient length of said one retaining channel to support a pluralityof modules associated with said floor portion.
 6. A system as recited inclaim 1 wherein a first number of said plurality of retaining channelsare disposed in retaining relation to a lower end of a plurality of saidmodules associated with said wall portion; a second number of saidplurality of retaining channels disposed in retaining relation to anupper end of a plurality of said modules associated with said wallportion.
 7. A system as recited in claim 6 wherein at least some of saidsecond number of retaining channels are disposed in interconnectingrelation to a plurality of modules associated with said roof portion ofsaid building.
 8. A system as recited in claim 7 wherein said at leastsome of said first number of retaining channels include a supportingflange extending outwardly therefrom into supporting relation with aplurality of said modules associated with said floor portion of thebuilding.
 9. A system as recited in claim 8 further comprising aplurality of fastener members extending in interconnecting relation withand at least partially through said first number of retaining channels,said lower end of said wall modules and corresponding ones of said floormodules.
 10. A system as recited in claim 8 further comprising aplurality of fastener members extending in interconnecting relation withand at least partially through said second number of retaining channelsand at least said upper end of said wall modules.
 11. A system asrecited in claim 6 further comprising a plurality of support stanchionssubstantially vertically oriented and extending in spaced relation toone another about at least a portion of a periphery of the building,between said first number and said second number of retaining channels.12. A system as recited in claim 1 wherein at least some of saidcomponent connectors include a tongue and a mounting plate fixedlyconnected in transverse relation to said tongue, said tongue insertableinto a correspondingly positioned one of the components of the buildingto define said tongue and groove connection therewith and said mountingplate disposed in interconnecting relation between said tongue and acorrespondingly disposed component of said building.
 13. A system asrecited in claim 12 wherein said mounting plate and said tongue areintegrally connected in perpendicular relation to one another.
 14. Asystem as recited in claim 12 wherein at least some of said componentconnectors comprise a key structure comprising a substantially planarconfiguration; said key structure including opposite end portionsdisposable in inserted relation with adjacently disposed ones of atleast some of said plurality of modules and at least partially defininga male-female connecting junction of said adjacent ones of saidplurality of modules.
 15. A system as recited in claim 14 furthercomprising a plurality of partition modules disposed in spaced,segregating relation to an interior of said building; said plurality ofpartition modules connected to one another by said key structure andinterconnected to others of said plurality of modules by said tongue andplate component connectors.
 16. A system as recited in claim 1 whereinat least some of said component connectors comprise a key structureincluding a substantially planar configuration; said key structureincluding free opposite end portions disposable in inserted relationwith adjacently disposed ones of at least some of said plurality ofmodules to define said tongue and groove connection therewith; saidtongue and groove connection at least partially defining a connectingjunction of said adjacent ones of said plurality of modules.
 17. Asystem as recited in claim 16 wherein said connecting junction furthercomprises an adhering material disposed in bonding relation between saidadjacent ones of said plurality of modules.
 18. A system as recited inclaim 1 wherein said plurality of modules comprise a plurality of roofmodules, adjacent ones of said plurality of roof modules connectedtogether and defining at least two roof sections; a ridge cap disposedand structured in interconnecting relation to corresponding sides ofsaid two roof sections.
 19. A system as recited in claim 18 wherein saidridge cap is at least partially inserted in interlocking engagement witheach of a plurality of roof modules defining said corresponding sides ofeach of said two roof sections.
 20. A system as recited in claim 19wherein each of said roof sections includes an outer side disposed in anat least partially supported relation to outer sides of said outer wallportion.
 21. A system as recited in claim 20 wherein at least some ofsaid plurality of retaining channels are disposed in retainingengagement with an upper end of said plurality of modules associatedwith said outer wall portion; said upper end retaining channels disposedin interconnecting relation with said outer sides of each of said roofsections.
 22. A system as recited in claim 18 wherein at least some ofsaid plurality of roof modules are structured to facilitate anon-penetrating attachment of a solar panel assembly on exterior,exposed portions thereof.
 23. A system as recited in claim 1 furthercomprising a water distribution assembly incorporated within thebuilding and including a reservoir disposed at an upper portion of thebuilding; said water distribution assembly further including a pluralityof distribution conduits disposed in fluid communication between saidreservoir and a plurality of water outlets associated with the building.24. A system as recited in claim 23 wherein said water distributionassembly is disposed and structured to direct water from said reservoirthrough said plurality of distribution conduits by gravity feed.
 25. Asystem as recited in claim 1 wherein said roof portion of the buildingfurther comprises a gutter assembly integrated therein and a pluralityof down spouts incorporated within the building in fluid communicationwith said gutter assembly.
 26. A system as recited in claim 1 furthercomprising a plurality of wall extensions disposed between an upper endof said wall portion and said roof portion; corresponding ones of saidretaining channels including at least one extension channel segmentdisposed in retaining engagement with a corresponding one of saidplurality of wall extensions.
 27. A system as recited in claim 1 whereinsaid building further includes a foundation including a plurality ofpilings, at least one of said pilings including a piling cap; at leastone of said component connectors disposed in interconnecting relationbetween said piling cap and a corresponding one of said retainingchannels; a plurality of connectors disposed in interconnectingengagement with each of said corresponding retaining channel, said onecomponent connector and said piling cap.
 28. A system as recited inclaim 27 wherein said plurality of connectors are fixedly secured tosaid piling cap and extend outwardly there from into saidinterconnecting engagement with said one component connector and saidcorresponding retaining channel.
 29. A system as recited in claim 1wherein said plurality of modules comprise a plurality of roof modules,adjacent ones of said plurality of roof modules connected together; atleast some of said plurality of roof modules formed of a one piecemolded construction.